Continuous process for preparing polymers

Abstract

A process for preparing polymers by continuous bulk polymerization in non-cylindrical channels is disclosed.

1 . A continuous bulk polymerization process for preparing polymers comprising: 
 providing at least one reaction mixture comprising at least one monomer, 
 wherein the reaction mixture contains substantially no solvent;  
   continuously feeding the reaction mixture to at least one non-cylindrical channel;    polymerizing the monomer in the non-cylindrical channel; and    continuously removing the polymer from the non-cylindrical channel; 
 wherein the temperature of the reaction mixture is controlled, and  
 wherein the non-cylindrical channel is not inside a reaction vessel.  
   
   
   
       2 . The process according to  claim 1  wherein the non-cylindrical channel is in heat transfer proximity with another channel containing a temperature control medium.  
   
   
       3 . The process according to  claim 1  wherein the temperature of the reaction mixture is controlled by continuously exposing the internal surface of the non-cylindrical channel to the reaction mixture, while simultaneously continuously exposing the external surface of the non-cylindrical channel to a temperature control medium.  
   
   
       4 . The process according to  claim 3  wherein the non-cylindrical channel is formed by plates.  
   
   
       5 . The process according to  claim 3  wherein the non-cylindrical channel is part of a heat exchanger selected from the group consisting of a plate-frame, plate-fin, and spiral-plate heat exchanger.  
   
   
       6 . The process according to  claim 3  wherein the non-cylindrical channel is part of a plate-frame heat exchanger.  
   
   
       7 . The process according to  claim 1  wherein the reaction mixture comprises an admixture of at least one monomer, and at least one initiator.  
   
   
       8 . The process according to  claim 1 , wherein said reaction mixture comprises a monomer selected from the group consisting of styrene, α-methyl styrene, butyl acrylate, methyl methacrylate, and (meth)acrylic acid.  
   
   
       9 . The process according to  claim 1  wherein at least two non-cylindrical channels are connected in a series or in parallel, and at least two reaction mixtures are fed to separate non-cylindrical channels.  
   
   
       10 . The process according to  claim 9  wherein at least two of the non-cylindrical channels are operated at different temperatures.